IBC CX 150 User manual

Quick Reference Installation Guide
For gas delivery to the boiler, we recommend using
hard piping rather than exible piping. If you use
exible piping, ensure that the gas pipe size is
appropriate for the maximum BTU input of the boiler.
Minimum Gas Pressure 4" w.c.
Maximum Gas Pressure 14" w.c.
Size piping for su󰀩cient sustained gas delivery at
su󰀩cient pressure to the boiler.
Recommended Supply Pressure at Full Load
Natural Gas 7"
Propane 10"
• Ensure that there is a minimum of 6 feet of piping
between the boiler and gas regulators.
• Use a manometer to test that gas delivered to the
boiler is delivered at su󰀩cient pressure and that
“lock up” does not exceed the maximum pressure.
• If using a 5 psi to inches vented gas regulator,
always oversize the vent pipe to prevent hunting
of the gas regulator when boilers are ring at
lower output levels.
• We strongly recommend against using copper gas
lines. In retrots with existing copper gas pipes,
we highly recommend replacing the pipes with
black iron or stainless steel piping sized correctly
for the boiler. If the copper gas pipes must remain,
clean and clear the gas piping of any debris before
connecting to the boiler. Failure to do so can
result in a blocked gas valve. and inconsistent
performance.
Maximum Pipe
Length by Model
½"
IPS
¾"
IPS
1"
IPS
1¼"
IPS
CX 150 (Natural Gas) 20’ 80’ 200' 900’
CX 150 (Propane) 50' 200' 600' 2,000’
CX 199 (Natural Gas) 10' 40' 150' 900'
CX 199 (Propane) 30' 125' 400' 1,400'
1. Place the vacuum breaker cap over the
vacuum breaker opening and push rmly
2. Fill the condensate trap with water.
3. Attach the trap to the drain hose, and tighten
the drain compression (including washer)
4. Slide the trap over the boiler drain outlet, and
tighten upper union nut. Secure the upper
union nut with the outlet clip.
5. Check for leaks.
Gas Supply (Section 3.12)
Boiler Mounting (Manual Section 3.4)
Venting (Sections 3.5 and 3.7)
• Ensure that sidewall congurations have a minimum
12" vertical separation, and that exhaust plumes are
well away from all building air intake vents.
• Ensure that all venting material is sloped towards
the boiler. PP venting must be sloped at a minimum
of ⅝″ per foot to ensure that no leaks occur via
gaskets.
• Ensure that PP venting is supported every 36″ (min).
• On longer horizontal runs of PVC and CPVC,
increase the grade to ⅜″ or more.
• Fully insert approved venting material into the
boiler’s exhaust outlet. Then, tighten the clamp
to lock the venting in place. For PP venting, a
transition adapter is not required.
• Pull on the venting to check it’s securely attached to
the boiler exhaust outlet.
Important: To protect against wind loads,
terminate exhaust venting as shown, or use the
appropriate direct vent kit.
Condensate Trap (Section 3.9)
LWCO Errors
To clear LWCO errors caused by air:
1. Ensure that there is no air trapped in the
boiler and boiler piping.
2. On the touchscreen controller Status Menu,
go to Clear Errors > Yes
1. Ensure that the boiler’s mounting bracket is
securely bolted to the wall structure.
2. Fasten the bottom of the boiler to the wall.
Important: Not applicable for construction
heating. Parts such as fans, burners, and
ignitors fouled by construction are not covered
under warranty.
120-414E1 CX Quick Start

1. Connect the boiler to a dedicated (max.)15
Amp breaker.
2. Wire incoming 120 VAC to the black and white
wires labeled “AC In” in the eld wiring box.
3. Ensure that the boiler is properly bonded
(grounded).
4. Refer to the “Wiring Diagrams” section in the
Inallation and Operating Inructions manual
• For multiple-boiler setup, use a secondary loop sensor.
• For zone valves or external peripherals such as wi-
thermostats, use external transformers.
Note: If a load is dened as Reset Heating, the
outdoor sensor is needed for proper operation.
Electrical continued (Section 3.13)
Water Piping (Section 3.11)
• Place air separators at the highest point.
• Install the pressure relief valve on the outlet
piping of the boiler in a vertical position. Do not
use an isolation valve between the boiler and
relief valve.
• Support all piping with appropriate piping
brackets.
• Plumb an appropriately sized expansion tank and
make up the water station into a tting on the
suction side of the circulator.
• Size boiler piping and pump for the BTU output of
the boiler.
For non-oxygen barrier piping sy󰀬ems, use a dirt
separator and/or a side-󰀬ream lter. Ensure that the
sy󰀬em is free of iron components, and treat with an
inhibitor.
We recommend that you always use a primary/
secondary piping conguration (see below for a basic
conguration).
In the case of hard water, use distilled or puried
water (but not reverse-osmosis). Glycol systems
must use propylene glycol. For large volume
systems, the optimum hardness is 0.6 to 1 grain.
Water Chemistry Allowable Limits
Acidity pH 6.6 - 8.5
Chloride < 125 mg/l
Iron < 0.3 mg/l
Copper < 0.1 mg/l
Conductivity < 400μS/cm (at 77°F / 25°C)
Water Hardness 0.6 to 1.75 grains/ gal
Load Setup
1. On the V-10 Touchscreen controller bottom
navigation bar, tap the Setup icon
2. Select a load and then select the load type.
3. Accept the defaults, or change any of the
settings.
You can nd more substantial settings in More >
Advanced Setup
4. Tap the Save button.
Manual Pump Purge
After the system is pressurized and you have
dened loads, perform a manual pump purge to
ensure air is purged.
On the touchscreen controller, go to More> System
Settings > Site Settings>Set Manual Pump Purge
to "On">OK > Save.
The manual pump purge runs until it is turned o󰀨, or
when there is a call for heat.
Electrical (Section 3.13)
(Appendix) for more information.
5. Wire the respective load pumps into the TB1
Terminal; for example, P/V 1, 2, 3, 4.
6. Wire thermostats or end switch dry contacts to
Therm 24 Vac, and then connect the other wire
to Therm 1, 2, 3, 4 corresponding to load pumps
P/V 1, 2, 3, 4.
7. No wiring is necessary for the On-Demand DHW
load.
Checklist
Treated water or Polypropylene glycol mixture in
the pipes.
□
Boiler system is pressured and ushed ≥ 8 psi. □
All gas connections soap-tested for leaks and now
leak free.
□
Voltage supply to the boiler tested for voltage
(nominal 120 Vac), polarity, and properly
grounded.
□
The boiler requires a dry set of contacts in the
Therm connections, an external sensor, or
External Control signal.
□
Boiler power turned on. □
Use “Setup” in the touchscreen controller to set up
the required loads. See above for instructions.
□
Steps followed in the “6.3 Commissioning” section
of the Installation and Operating Instructions
manual.
□
Completed the Installation & Commissioning
Report in manual - Combustion Test recorded.
□
Veried a CO alarm is installed and operational □
①Closely-spaced tees: install tees with straight piping
(minimum lengths are shown in pipe diameters), tees
maximum four pipe diameters apart with no restrictions
between ttings